As someone who sews, this entire armor making process made me a nervous wreck. Especially since I am large busted and I found how unforgiving the sintra could be. I plowed through the forums to find ideas of how to best approach this process and somehow landed on a post where the person used paper packing tape. It sounded kind of crazy because I didn't realize what the tape was exactly. Paper packing tape, the old school kind that you have to wet, is actually infused with strands of fiberglass. I thought, why not?!
SO, I invited my mom over and cut a billion small, medium and large strips of the stuff, which I had ordered from walmart. I put on an old t-shirt and we got to work. I had her cover the entire front of the shirt with me in it. It was not fun. I could NOT move once it started drying. It was like a body cast. No joke. Once it dried, she double checked that each area had multiple layers covering it and that it was a smooth as it could be. The shirt was then cut off via the back and I carefully shimmied my way out.
I then began to draw out where I wanted to cut for the chest pieces and ab pieces.
20180807_144533 by
allred.sarah, on Flickr
I decided on the beginning lines with help from my clan members, and added a bit of extra to each side. You can take away but you can't add it back! lol
20180819_121134 by
allred.sarah, on Flickr
I then went out and got myself a can of fiberglass resin and some fiberglass cloth. Thankfully this was done in the summer and I could do it all outside. That stuff is nasty! I added a first layer of just the resin on inside and out of the pieces. I then cut strips of the cloth and did another layer with the cloth. I did a total of 3 layers of cloth to ensure I would have enough to sand down. The cloth was only added to the outer surface of the pieces. This took a while due to dry/cure times.
IMG_20180825_133157 by
allred.sarah, on Flickr
I then wen to work trimming off rough bits and began the sanding process. This took FOREVER. I learned to quickly love sanding. I don't know that I have many photos anywhere of this process because I was constantly covered in sanding dust.
I added bondo filler where it was needed to fill in low spots and then did a layer of primer to help myself see low/high points and rough spots.
The ladies were a little lumpy here. I had clan members help me figure out what needed trimmed up. I also ended up trashing the original ab plate and collar and going with sintra ones at this point.
wippics by
allred.sarah, on Flickr
armorwip by
allred.sarah, on Flickr
I went back to work sanding and filling and sanding and filling until I was more pleased with the product.
The ab plate and collar ended up needing trimming and I evened those up to match the lines of the final chest shapes. I then added industrial velcro to my vest and plates for a means of attaching. I plan on eventually finding a more permanent means of attaching, but velcro is holding up incredibly well to the rigidness of the chest plates.
On to other pieces...
I ordered a helmet from TMA. But I put off working on it much. I did a huge amount of sanding while the weather was still nice and then I set it to the side to be completed later on.
I also ordered a couple things from a friend of mine who does 3d prints. I had tried desperately to make knees out of sintra, but evidently sintra hates me. I ordered a set of knees from my friend.
knees by
allred.sarah, on Flickr
knees2 by
allred.sarah, on Flickr
This next one was prior to filler primer and another fun time sanding.....
20181218_212709 by
allred.sarah, on Flickr
Mostly finished minus some minute touch ups.
kneeswip by
allred.sarah, on Flickr
The knees are attached via a strip of industrial velcro and a strap that is hidden by weaving through a hole in the seam of the pants and out the other side to attach under the knee.
I also ordered a DL44 blaster from the same person. Once again....I sanded. It was becoming like a meditation.
20190104_201425 by
allred.sarah, on Flickr
First stain on the wood filament grips and first big sanding pass.
20190126_121020 by
allred.sarah, on Flickr
Second, darker, staining of grips.
20190126_115717 by
allred.sarah, on Flickr
After much sanding, layers of paint and some rub n buff.
20190130_152136 by
allred.sarah, on Flickr
Now for the shoulders and gaunts.
I used a basic shoulder armor pattern to cut sintra pieces out and then beveled the edges a bit with my dremmel. I added a layer of silver, then black. I then painted the mythosaur on one and the BMG logo on the other in the colors I chose for the whole kit.
20190120_122513 by
allred.sarah, on Flickr
20190120_122438 by
allred.sarah, on Flickr
For the gauntlets, I wanted it to be simple and streamlined. I have incredibly tiny wrists, and felt that a large or bulky gauntlet would look strange on me. I used a similar method to the toilet brush holder method I have seen around. I found thick and sturdy plastic tumblers and cut off the bottoms of them. Sanded off the rough edges and primed them. I put on the two layers of silver and then the flat black. I added a similar paint theme as I had on my knees.
I had to move on to the entire paint job. This was tough. I wanted to keep a lot of black. I wanted gold to show up and red not be overbearing due to the use of red in the soft parts. What I came up with was angular and relatively simple. I threw on two layers of silver, then a flat black.
20181125_171740 by
allred.sarah, on Flickr
20190112_172218 by
allred.sarah, on Flickr
20190112_164523 by
allred.sarah, on Flickr
20190120_122357 by
allred.sarah, on Flickr
I finally got to work on the helmet. I ordered a set of tactical ACH pads for the inside and a Kalevala visor in gold and red (I couldn't choose!). I trimmed out the front except for about 1.5 inches at the bottom to keep the shape right while working. I painted on two layers of silver and then the flat black. I added similar lines as my armor and painted in the cheek hollows. I also added my chosen name Te'isa A'den on the back right.
20180822_142102 by
allred.sarah, on Flickr
20190126_120944 by
allred.sarah, on Flickr
helmetwip by
allred.sarah, on Flickr
20190127_151912 by
allred.sarah, on Flickr
The belt is a thrift belt that has been dyed black and had a removable buckle. I added some leather pouches found in an army navy surplus store that came in black. I added a plain flat buckle that a friend had used for another Star Wars costume.
20190120_122357 by
allred.sarah, on Flickr
There are some small things that need to be finished up. I have to trim the visor and a bit of the helmet. I also need to either find different gloves or stitch a bit of fabric in to cover the small hole it shows on the back of my hand.
IMG_20190201_192212_871 by
allred.sarah, on Flickr
